Metallizing & Thermal Spray Coating Services

When long-term corrosion protection matters, metallizing is one of the most effective coating solutions available. At T BAILEY LLC, our certified coatings department provides advanced thermal spray coating and thermal spray metalizing services for fabricated steel parts, components, and large-scale structures. Established in 2003, our coatings department operates within a dedicated 14,000-square-foot area at our fabrication facility, giving clients access to a streamlined, high-quality solution for surface preparation, coating, inspection, and delivery.

Our goal-oriented team is experienced in applying metallizing coatings to a wide range of fabricated steel products using advanced technology and proprietary innovations. Whether you need protection for tanks, piles, bridges, marine structures, pylons, or other industrial steel components, T BAILEY LLC delivers metallizing services built around durability, performance, and schedule.

What Is Metallizing?

The metallizing process uses two electrically charged zinc, aluminum, or other metal wires of opposite polarity. When the wires meet, they atomize into a molten arc. That arc is then propelled onto the steel substrate using compressed air, creating a highly durable metal spray coating. As described in our field experience, the process is similar to a flame spray application, where the metal is atomized and deposited directly onto the prepared surface to form a bonded protective layer.

This form of thermal spray application offers several important advantages:

• Size flexibility: Unlike galvanizing, metallizing can be applied to large structures that do not fit in a galvanizing kettle.
• Fast return to service: Because the coating solidifies instantly, projects can move quickly through production or back into service.
• Portable application: Metalizing spray equipment can be used in the shop or in the field on immovable structures such as bridges and marine facilities.
• Versatility: Metallized surfaces can provide corrosion protection, anti-slip or non-skid enhancement, surface repair capability, and can be top-coated in color.
• Durability: Metallized coatings range from light-duty to heavy military-grade systems and are designed to withstand demanding weather and environmental conditions.

Together, these advantages make metallizing a highly effective solution for protecting steel structures that require long-term corrosion resistance, flexible application, and dependable performance in demanding environments.

Benefits of the Metallizing Process

When you choose T BAILEY LLC for metallizing thermal spray services, you gain more than a coating; you gain long-term value and protection for your steel structures.

Key benefits include:

• Enhanced corrosion protection: Rust weakens steel over time and affects appearance, safety, and service life. Metallizing corrosion protection helps inhibit rust and can extend a structure’s service life by approximately 20 years.
• Increased durability: Thermal spray metal coating systems offer strong adhesion and resist cracking, flaking, peeling, and blistering.
• Electrical conductivity: Since most non-metallic materials are not electrically conductive, metallization can provide a pathway for electric current where needed.
• Weather resistance: Metalized coatings create a protective barrier against severe weather and harsh operating environments.
• Reduced maintenance costs: Compared with conventional coatings that require more frequent repainting, metallizing coatings reduce long-term upkeep needs.
• Better performance in harsh outdoor conditions: Based on project experience, metallizing handles UV exposure and temperature changes well, making it a strong choice for marine, industrial, and transportation applications.
• Faster turnaround: Because the coating solidifies immediately, metallizing can reduce downtime and help projects move through fabrication, finishing, and delivery more efficiently.

For owners and contractors alike, these benefits make metallizing a practical, long-term investment in the safety, durability, and lifecycle performance of steel assets.

What Are the Various Metallization Processes?

There are several types of metalization and related coating systems used across industries. These include:

• Vacuum metallizing: The coating material is vaporized inside a vacuum chamber, and the vapor condenses onto the substrate.
• Hot-dip galvanizing: Steel is immersed in a galvanizing kettle filled with molten zinc, forming a layered zinc and zinc-iron alloy coating.
• Zinc spraying: A heated gun melts zinc and sprays it onto the substrate using combustion or compressed air.
• Thermal spraying: Various thermal-spray coating methods use plasma or combustion to deposit heated or molten material onto a surface.
• Cold spraying: A supersonic gas jet accelerates unmelted metal powder onto a substrate, where the particles deform and adhere.

These options all fall under the broader category of thermal spray metalizing or related protective coating technologies, but the right system depends on project size, location, service environment, and long-term maintenance goals.

Different Types of Coating Systems

T BAILEY LLC performs both galvanizing and metallizing, and understanding the difference between these coating systems is important when selecting the right solution for your project.

Galvanizing

Steel is hot-dipped in a galvanizing kettle containing ASTM B6 graded zinc, producing a multi-layered coating of zinc/zinc-iron alloy. After cooling, steel may undergo post-treatment enhancements. This creates a uniform, corrosion-resistant coating that is cost-effective and long-lasting. However, the process is limited by kettle size, and regalvanizing is generally inadvisable.

Metallizing

Two electrically charged zinc, aluminum, or other wires of opposite polarity are fed through a metalizing machine. On contact, an atomized molten arc is propelled and deposited using compressed air. Surface preparation requires abrasive blasting to achieve a sharp, angular profile. Metalizing meets industry standards, including SSPC, AWWA, and NACE, and in many applications, it is superior to galvanizing. In many systems, the metallized surface is then followed by a seal coat and paint coat, creating a layered protection system that enhances long-term corrosion resistance and overall coating performance.

Considering Different Coating Systems

Metalizing and galvanizing are both coating systems that can be applied along with an additional coating as part of a duplex coating system. Each option comes with its own advantages and disadvantages, and the right choice depends on your project’s size, service environment, corrosion exposure, and maintenance needs. For many large, exposed, or immovable steel structures, metallizing services offer greater flexibility, better field applicability, and stronger long-term value. For more information about our metallizing services, contact T BAILEY LLC today.

What Is Galvanizing?

Hot-dip galvanizing is the process of immersing steel in a zinc bath to produce a corrosion-resistant, multi-layered coating of zinc-iron alloy and zinc metal. The galvanizing kettle contains zinc specified to ASTM B6, which defines the grade of zinc used in the process.

In some cases, additional metals may be added to the zinc in accordance with the desired coating system. Once removed from the kettle, the steel is cooled and may undergo further post-treatment steps depending on the coating specification. This process creates uniform thickness and long-lasting corrosion protection at a reasonable cost.

The process is inherently simple, but it does come with limitations. Because galvanizing involves dipping steel into multiple kettles, there are size restrictions on what can be processed. Depending on your project’s final dimensions, metallizing or partial galvanizing may be a better option. In addition, once an item has been galvanized, it is difficult to regalvanize it later if repairs become necessary.

High-Quality Preparation for Metallizing

At T BAILEY LLC, quality control is built into every stage of the metallizing process.

T BAILEY LLC Maintains Quality Control in All Processes

As a specialist among metallizing suppliers, we implement a Quality Management System to control all aspects of production. Our coatings facility is AISC certified with all three Sophisticated Paint Endorsements. Additionally, we are an SSPC QP3 Certified Contractor for shop-applied coatings. We perform daily monitoring and check details ranging from cleanliness to dry-film thickness of our applied coatings.

We are Committed to On-Time Product Delivery

T BAILEY LLC is committed to meeting all contract requirements and addressing any customer concerns. We work toward continual improvement through rigorous self-examination and by controlling the quality of materials, workmanship, parts, and supplies we produce or procure on behalf of our customers.

We Follow International Standards & Inspection Protocols

To maintain our commitment to quality, we undergo annual recertification through third-party external audits. Our specialized technicians are trained to high standards and are encouraged to continually update and improve their expertise. We also employ internal Certified NACE Level III Coatings Inspectors to help maintain our ratings in both the United States and Canada.

Common Industries that Use Metalized Equipment

Because metallizing thermal spray systems provide reliable long-term protection, they are used across a broad range of industries and applications, including:

• Oil and gas refineries and offshore structures
• Wind towers
• Municipal water towers
• Military (Army Corps of Engineer applications)
• U.S. waterways
• Bridges
• Department of Transportation projects
• Facilities maintenance
• Maritime and marine
• Power generation
• Medical devices
• Agricultural equipment
• Food production equipment
• Automotive parts and manufacturing
• Data centers, cloud computing, and printed circuit boards

These applications reflect where thermal spray aluminum coating, thermal zinc spray, and other metal spray coating systems are most valuable: environments where steel is exposed to moisture, weather, salt, or demanding service conditions and where long-term protection is essential.

T BAILEY LLC:  Metallizing Solution for Coating System Needs

With our decades of experience, T BAILEY LLC confidently provides durable, cost-effective metalized coatings for a wide variety of applications. We can metallize your steel structure from the smallest components to colossal constructions. If you cannot bring your project to us, we can bring our metallizing services to you.

Whether you are looking for thermal zinc spray, thermal spray aluminum coating, or a complete metalizing process for long-term corrosion protection, T BAILEY LLC has the facilities, certifications, and experience to support your project. Explore our industrial coatings services, learn more about our steel fabrication capabilities, or contact T BAILEY LLC today to discuss your metallizing requirements.